Hardware Engineer &
Full-Stack IoT Developer
Hardware Engineer with 5+ years delivering production-ready IoT solutions and 8+ years in electrical engineering. I've delivered 2000+ manufactured units, managed 1000+ device fleets, and built systems handling real-time data for critical operations. From hardware design to cloud infrastructure, I create end-to-end solutions that scale.
Manufactured
Managed
Control Systems
Solutions
Core Technical Expertise
Full-stack capabilities spanning hardware design, embedded systems, cloud infrastructure, and production-scale manufacturing.
Lead IoT Engineer
Do It Technologies - Smart IoT Switch
Designed and created a complete IoT solution consisting of 4 separate PCB assemblies to control 2 mains voltage high current relays (25A). The system allows users to trigger and schedule relay operations through an Android application.
This project involved full-stack development from hardware design to cloud infrastructure. I handled the complete product lifecycle from conception to production, with the first batch of 1000 units successfully manufactured. The device was designed with CE Certification requirements in mind.
The system uses Firebase as the communication bridge between devices and the mobile application, ensuring real-time synchronization and reliable operation. The firmware was developed using FreeRTOS and ESP-IDF framework, implementing secure MQTTS communication with remote task logging capable of handling approximately 15 messages per second.
Technical Implementation
The project required innovative design solutions due to volume restrictions, leading to a modular 4-PCB architecture that maximizes functionality while maintaining compact form factor. A complete backend was built using FastAPI, with DevOps & CI/CD for application monitoring and deployment using Docker.
Hardware & Design
- 4 separate PCB assemblies design
- 25A mains voltage relay control
- Volume-optimized component layout
- BoM creation and component sourcing
- Production planning (2000+ units)
Software & Infrastructure
- ESP32-C3 firmware with FreeRTOS & ESP-IDF
- MQTTS with remote task logging (~15msg/sec)
- Google Firebase integration
- FastAPI backend with PostgreSQL
- DevOps: Docker, Nginx, GitHub Actions
- Application Monitoring & Deployment
FULL STACK DEVELOPMENT
CheckInSmart - CheckInSmart Hospitality Platform
Architected and developed a comprehensive all-in-one hospitality management platform that revolutionizes the guest experience from booking to checkout. The platform serves 100+ properties, reducing check-in processing time by 80% through contactless digital processes while increasing guest satisfaction scores and generating 35% more revenue through integrated local services and experience booking capabilities.
Built as a complete digital ecosystem that eliminates traditional hospitality pain points through contactless check-in, digital key management, integrated concierge services, and automated guest communications. The platform handles everything from ID verification to local experience bookings, with real-time synchronization across multi-property management systems.
Core Platform Features
Guest Experience
- Contactless digital check-in/check-out
- Secure digital key delivery to mobile devices
- ID verification and document processing
- Integrated transportation booking
- Local dining and experience recommendations
- 24/7 digital concierge services
Property Management
- Real-time property dashboard with analytics
- Automated guest communication workflows
- Multi-property management interface
- Room status and occupancy tracking
- Revenue optimization through partnerships
- Guest feedback and review management
Technical Architecture
Frontend & UX
- Responsive web application with mobile-first design
- Progressive Web App (PWA) capabilities
- Multi-language support and localization
- Accessibility-compliant interface design
Backend & Infrastructure
- Flask web framework with RESTful API design
- PostgreSQL database with optimized queries
- Google Cloud deployment with auto-scaling
- Booking.com and WhatsApp Business API integration
- Secure payment processing and PCI compliance
FULL STACK IOT ENGINEER
EMDOT S.A. - Smart Waste Management Platform
Developed a comprehensive IoT platform for managing over 1000 waste collection devices across multiple locations. The system provides real-time monitoring, device configuration, and GPS-based visualization of waste collection operations.
Designed an Ultra-High-Accuracy ADC for dynamic weighting applications. Implemented a robust security architecture using JWT authentication for device authorization and created a complete web dashboard for fleet management. The platform significantly improved operational efficiency by 35% and provided valuable analytics for waste collection optimization.
System Architecture
The platform handles multiple communication protocols including WiFi, LoRaWAN, and NB-IoT, ensuring reliable connectivity across diverse deployment environments. Data optimization was achieved through binary C struct transmission over MQTT using IPv6, reducing bandwidth usage by 40% while maintaining real-time responsiveness for 24/7 operations management.
Hardware Development
- PCB design using Altium Designer
- Multi-platform firmware (PIC, STM32, Nordic)
- IoT communication protocols (WiFi, LoRaWAN, NB-IoT)
- Enclosure and wiring system design
- Vehicle integration solutions
Software Platform
- JWT-based device authentication
- MQTT broker implementation
- Web dashboard with GPS visualization
- Binary data parsing and management
- Individual device authorization system
Lead Hardware Engineer
Gemitech - Advanced 3D Printer Head PCB Design
Designed specialized 6-layer mixed signal PCB solutions for custom industrial 3D printer heads used in advanced material science applications. Implemented precision thermal management enabling consistent material deposition at 0.01mm tolerances for research and development in material engineering.
This cutting-edge project required designing the electrical control panel and detailed manufacturing plan for the industrial 3D printer. Created an adjustable 300W DC/DC Power Stage with H-Bridge PCB featuring voltage & current feedback for accurate load control. Led procurement and validation of over €40,000 worth of components required for the first production run.
Technical Specifications
Design Requirements
- 6-layer mixed signal PCB design
- 0.01mm tolerance thermal management
- 300W DC/DC Power Stage with H-Bridge
- Voltage & current feedback control
- Electrical control panel design
- Cable assemblies for subcontractor manufacturing
Production & Procurement
- €40k+ component procurement & validation
- Detailed manufacturing planning
- Multi-material extrusion capability
- Real-time monitoring systems
- Industrial-grade reliability
- Modular expansion design
The PCB design incorporates advanced thermal management and precision control circuits to ensure consistent material deposition at the cellular level, pushing the boundaries of what's possible in industrial 3D printing technology.
Production Engineer
ELVEM P.C. - Medical & Pharmaceutical Equipment
Designed and manufactured specialized sterilization equipment and stability chambers for the medical and pharmaceutical industry. This role combined precision engineering, manufacturing expertise, and quality control to deliver critical equipment for healthcare applications.
Responsible for small-scale production runs, ensuring each unit met stringent medical industry standards. Developed custom solutions including 3D printed and metal jigs for optimal HVAC pipe routing and testing, improving assembly efficiency and product reliability.
Key Responsibilities
Manufacturing & Production
- Design & manufacturing of sterilization equipment
- Stability chambers for pharmaceutical applications
- Small-scale production run management
- Quality control and testing protocols
- Medical industry compliance standards
Custom Tooling & Fabrication
- Custom 3D printed jigs & assemblies
- Metal jigs for HVAC pipe routing
- Testing fixture design and fabrication
- Optimized assembly workflows
- Precision metalworking operations
Technical Expertise
Metalworking Equipment
- Lathe operations
- Mill operations
- Brake press operations
- Various metal fabrication equipment
- Precision machining techniques
Control Systems
- PCB version of stability chamber control system
- HVAC integration and control
- Temperature and humidity monitoring
- Automated control sequences
- System calibration and validation
This role provided comprehensive experience in manufacturing processes, from initial design through production and quality assurance, working with equipment critical to medical and pharmaceutical operations.
Featured Project Outcomes
End-to-end solutions delivered from concept to production scale
Do It Technologies
Led the end-to-end development of a high-power IoT switch, from concept to manufacturing 1,000+ units. Achieved robust 25A mains voltage control by engineering an innovative 4-PCB modular design to overcome strict physical volume limitations.
- Achieved 25A high-current switching capability
- Optimized 4-PCB design for volume constraints
- Built complete CI/CD deployment pipeline
- Established ongoing support & maintenance
CheckInSmart
Developed a comprehensive property management platform from the ground up to automate operations for 100+ Airbnb listings. Engineered a custom booking engine with WhatsApp and Booking.com API integrations, cutting administrative tasks by 80% and eliminating double-booking errors.
- Reduced admin workload by 80% automation
- Served 100+ properties with real-time sync
- Integrated WhatsApp & Booking.com APIs
- Deployed on Google Cloud with CI/CD
Gemitech
Led the complete hardware lifecycle for a precision 3D printer head, from initial PCB design to final fabrication. Managed the entire procurement process, including component sourcing and supply chain logistics, while overseeing manufacturing to ensure high-precision, reliable performance for advanced material science applications.
- Enabled microscale precision printing
- Advanced thermal management systems
- Research-grade material science applications
EMDOT S.A
Engineered an enterprise IoT platform to monitor 1,000+ waste collection devices, boosting operational efficiency by 35%. The system featured real-time GPS tracking and was secured with a robust MQTTS and JWT authentication architecture.
- Managed 1000+ devices across multiple sites
- Improved operational efficiency by 35%
- Implemented secure JWT authentication
- Designed an ultra-high-resolution ADC for precise dynamic weight measurement
ELVEM P.C.
Designed and manufactured specialized sterilization equipment and stability chambers for the medical and pharmaceutical industry. Managed small-scale production runs while developing custom 3D printed and metal jigs for optimal HVAC pipe routing, testing, and assembly processes.
- Medical-grade sterilization equipment
- Pharmaceutical stability chambers
- Custom tooling and jig fabrication
- PCB control system development
Proven Track Record
Delivering measurable impact across the full product lifecycle
Hardware to Production
From PCB design to 2000+ unit manufacturing runs, ensuring scalable, cost-effective production.
Enterprise Scale
Built systems managing 1000+ IoT devices with real-time monitoring, JWT security, and 99.9% uptime.
Measurable ROI
Consistently deliver 35%+ efficiency improvements through automation and optimized system architecture.
My Experience
My Education
Personal Projects & Expertise
Continuous learning and self-improvement through hands-on projects
Let’s work together!
Ready to discuss your next IoT project? I'd love to help bring your innovative ideas to life through expert hardware design, firmware development, and full-stack solutions.
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Phone
+30 698 891 6026 -
Email
info@gkalampakas.eu